U.S. patent number 5,068,962 [Application Number 07/618,846] was granted by the patent office on 1991-12-03 for method of fabricating an energy meter.
This patent grant is currently assigned to General Electric Company. Invention is credited to Peter F. Coryea, Warren R. Germer, Jacob M. Stillwagon.
United States Patent |
5,068,962 |
Germer , et al. |
December 3, 1991 |
Method of fabricating an energy meter
Abstract
An output connection and signal conditioning circuit board is
selected and detachably connected to an electronic energy meter to
customize its functions. Connectors are provided at the ends of the
circuit board to mate with an edge connector in the bezel of the
register and spaced holes in the base. A separate flexible
connection to the KYZ terminals is provided, along with an
intermediate tab and slot to position the circuit board and
strengthen the meter. A selected circuit board is added to the
manufactured meter to meet customer requirements by inserting a pin
connector at the bottom of the circuit board through the spaced
holes, and rotating the circuit board to mate with the tab and the
edge connector.
Inventors: |
Germer; Warren R. (Dover,
NH), Coryea; Peter F. (Salem, NH), Stillwagon; Jacob
M. (Nottingham, NH) |
Assignee: |
General Electric Company
(Somersworth, NH)
|
Family
ID: |
27021746 |
Appl.
No.: |
07/618,846 |
Filed: |
November 28, 1990 |
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
412351 |
Sep 25, 1989 |
|
|
|
|
Current U.S.
Class: |
29/830; 361/773;
361/665; 324/114; 324/142; 324/156; 439/167 |
Current CPC
Class: |
G01R
11/02 (20130101); G01R 22/065 (20130101); H05K
1/18 (20130101); Y10T 29/49126 (20150115) |
Current International
Class: |
G01R
11/04 (20060101); G01R 11/00 (20060101); G01R
11/02 (20060101); H05K 1/18 (20060101); H05K
003/36 () |
Field of
Search: |
;361/405,370 ;29/840,846
;439/166,167 ;324/132,114,156 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Arbes; Carl J.
Attorney, Agent or Firm: Brunson; Robert E. Freedman; Irving
M.
Parent Case Text
This is a divisional of copending application(s) Ser. No.
07/412,351 filed on 9/25/89, now U.S. Pat. No. 4,894,734 issued
Feb. 19, 1991.
Claims
What we claim is:
1. A method of fabricating or retrofitting an electronic energy
meter with selected signal functions for connection in circuit with
a source of power and a load to be metered and utilizing industry
standard base connections, and a register assembly with associated
electronics adapted to be customized at the time when customer
requirements and needs for the signal functions are identified,
comprising the steps of:
assembling a general purpose electronic energy meter including a
base assembly meeting an industry standard configuration;
positioning a register assembly including electronic circuitry
above and spaced from said base assembly;
connecting a multi-pin edge connector on said register assembly to
said electronic circuitry with the pins of said edge connector
extending parallel to said register assembly;
providing multiple spaced apertures through said base;
manufacturing a plurality of types of register circuit boards
configured to provide differing desired signal functions and sized
to connect between said edge connector and said multiple spaced
apertures in said base below said edge connector, each of said
circuit boards configured with a second connector at the top
thereof to mate with said edge connector and provided with a third
connector at the bottom thereof including a plurality of spaced
pins adapted to pass through said spaced apertures in said
base;
subsequently customizing said electronic energy meter by:
selecting an appropriate register circuit board to provide the
desired signal functions;
inserting said spaced pins of said third connector through said
spaced apertures in said base; and
moving said second connector into contact with said edge connector;
whereby selected signal processing and connections are provided
between said register assembly and the exterior of said electronic
energy meter through the base thereof.
2. The method of fabricating an electronic energy meter of claim 1
comprising the additional steps of providing a tab extending from
said energy meter in the region between said base assembly and said
register assembly, and an opening in said circuit board in the
central region thereof, and moving said opening toward and around
said tab while moving said second connector into contact with said
edge connector.
3. The method of fabricating an electronic energy meter of claim 2
wherein a second circuit board is provided for said register
assembly and positioning said multi-pin edge connector on said
second circuit board.
4. The method of fabricating an electronic energy meter of claim 3
wherein said industry standard base connections include KYZ
terminals, and comprising the additional steps of providing a
fourth connector, and connecting said fourth connector to said KYZ
terminals in the base by flexible connections.
5. The method of fabricating an electronic energy meter of claim 3
comprising the additional step of selectively providing a 3 pin
connector on the bottom of certain of said register circuit
boards.
6. The method of fabricating an electronic energy meter of claim 5
wherein said register circuit board is selectively removable for
repair, replacement, or substitution purposes through the
additional steps of:
disconnecting said second connector from said edge connector with
rotation of said register circuit board about the spaced pins of
said third connector in said spaced apertures through said
base;
removing said opening in said circuit board from around said tab;
and
lifting said register circuit board to remove said spaced pins of
said third connector from said spaced holes in said base.
7. The method of fabricating an electronic energy meter of claim 2
wherein said tab in said opening is positioned to resist the thrust
of an external connector being pressed into contact with said pins
of said third connector to prevent the transmission of said thrust
through the register circuit board to said edge connector.
8. The method of fabricating an electronic energy meter of claim 1
wherein the moving of said second connector into contact with said
edge connector is accomplished by rotation of said register circuit
board about the pins of said third connector in said spaced
apertures.
9. The method of fabricating an electronic energy meter of claim 8
wherein said register circuit board extends between said base and
said register and assists in supporting and positioning said
register assembly relative to said base.
10. The method of fabricating an electronic energy meter of claim 9
including the additional step of securing a fifth connector
positioned outside said energy meter to said spaced pins which
extend through said base to complete electrical connections from
the outside of said energy meter through said base to said register
assembly.
Description
BACKGROUND OF THE INVENTION
Present day electronic energy meters and registers have greatly
expanded capabilities and are being called upon to provide
additional functions beyond simple indications of kilowatt hour
consumption and kilowatt demand. Examples of such additional
functions are pulse initiators, time of use rate period
indications, end of demand interval indicator, load control
signals, a demand threshold indicator, and an external control
signal to inhibit accumulation of pulses in various register modes.
In addition, the relative complexity of such electronic meters,
which include microprocessors and data processing circuitry,
requires the use of sophisticated electronic test equipment in the
repair of such meters. It has become necessary to provide external
signals to an electronic energy meter, and to bring electronic
signals out of the electronic energy meter. However, many of the
connections, configurations, and dimensions of an energy meter are
defined by industry standards, namely the American National
Standards Institute (ANSI) standards. For example, some transformer
rated versions of the ANSI standard S-base meter have provisions
for the pulse initiator KYZ output connections to be made through
spare terminals in the meter. Various approaches have been
suggested or utilized to provide additional means for bringing
signals into or out of electronic energy meters. One method has
been to provide a short multi-conductor cable protruding through a
hole in the base of the meter and terminating in a connector which
then can be connected to external equipment. However, not every
energy meter requires external signals such that it is desirable to
have a standard energy meter which is flexible in enabling external
signals to be provided by the manufacturer at the time of
manufacture, or to be added later by the end user or by the
manufacturer. That is, it is highly desirable to have the
flexibility built into a standard energy meter for later
customizing as required, including the ability to provide or
connect to external signals.
In addition, electronic energy meters are constructed in a layered
configuration with the socket or base forming the bottom layer, and
the register or meter which provides the readings at the top layer.
Also, there may be one or more intermediate layers of electronics,
such as electronic circuit boards, provided. It is important that
the construction of such layered meters be provided with proper
structural support and integrity. While external signals may be
connected to a plurality of layers in the energy meter, it is
highly desirable that the external connector be provided through
the base of the meter.
In addition, the control signals in an electronic energy meter are
often not suitable for direct use outside the meter, and electronic
signal conditioning is generally required. In those meters where
external signals are required, it is desirable that the signal
conditioning circuitry be added to the interior of the energy
meter. It is also desirable to provide for the additional signal
conditioning circuitry to be selectively added by the manufacturer
during or after manufacture, or by the end user after delivery, and
even use of, the energy meter. The cost of manufacturing electronic
energy meters and the delivery cycle can be reduced if a standard,
but flexible meter can be manufactured and stocked with the various
customer requirements and features later, and selectively added;
that is, providing the ability to accommodate the late point
identification of features.
OBJECTS AND SUMMARY OF INVENTION
It is an object of the present invention to provide the flexible
capability to an electronic energy meter to selectively add
external signal connections.
It is another object of the present invention to provide for
flexible addition of external signal connections in an electronic
energy meter including provisions for the addition of signal
processing within the meter.
It is still another object of the present invention to provide the
capability to flexibly add external signal connections to an
electronic energy meter, while maintaining and enhancing the
structural integrity and strength of the meter.
It is yet another object of the present invention to provide a
signal conditioning circuit board in an electronic energy meter
which enhances the structural integrity of the meter.
It is a further object of the present invention to reduce cost and
the length of the delivery cycle between identification of the
features required by a customer and completion of the meter.
In accordance with one embodiment of the present invention, a
signal conditioning and connection assembly is provided to
customize an electronic energy meter by connecting the register
assembly of the meter through its base for connection to external
circuitry. The base of the meter includes a plurality of spaced
holes and the register circuit board includes an edge connector in
an aperture in the meter bezel. A register circuit board is
selectively connected to provide signal conditioning between the
register and the outside of the meter through connectors on the
register circuit boards mating with the register edge connector on
the upper end, and pins passing through the spaced holes on the
bottom. A tab intermediate to the base and register cooperates with
an aperture in the register circuit board to facilitate positioning
and retention of the circuit board. The register circuit board is
selectively connected by inserting the pins into the spaced holes,
and rotating the board until the tab passes through the aperture,
and the upper connector mates with the edge connector. Another
connector on the circuit board enables selective connection through
the KYZ terminals in the meter base.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a drawing of an electronic energy meter incorporating the
present invention.
FIG. 2 shows the interior of the base of the energy meter of FIG.
1.
FIG. 3 shows a register circuit board used in the electronic energy
meter of FIG. 1.
FIG. 4 is a side view of the register circuit board of FIG. 2.
FIG. 5 is a side view of a section of FIG. 1 taken along the line
5--5 in FIG. 3.
FIG. 6 is an enlarged view showing the connector provided for
external connections in the base of the energy meter of FIG. 1.
Referring to FIG. 1, an electronic energy meter 2 is shown
schematically as including a base module 4, an electronic or
voltage module 6, and a register or indicator module 8. A plurality
of supports 12 supports the voltage module 6 in spaced relation to,
and upon, the base module 4; while a plurality of supports 14
support the register module 8 in spaced relation to, and upon, the
voltage module 6. The base module 4 includes a plurality of circuit
terminals such as 18 and 20 which project through the base of
module 4 to the interior of the meter. The size, location and usage
of the plurality of the circuit terminals such as 18 and 20 are
dictated by the American National Standards Institute (ANSI)
standards such as ANSI standard C12.10-1978. Details of the
construction of an electronic energy meter which incorporates the
present invention are set forth in copending U.S. Pat. No.
5,001,420 Modular Construction For Electronic Energy Meter assigned
to the same assignee as the present invention, and hereby
incorporated by reference. In accordance with one embodiment of the
present invention, the internal control signals of the register 8
are all brought to an edge connector 24 at one side of the register
circuit board 26 of the register 8. The male terminals such as 28
extend radially outward from, and parallel to, the register circuit
board 26. The edge connector 24 is positioned within an aperture 32
formed within the bezel 34 of the register 8. The edge connector 24
includes in one embodiment two parallel rows of 9 connectors each,
for a total of 18, although all of the connectors are not shown in
FIG. 1.
The base module 4 includes a base connector housing 38 with a
plurality of small holes, 16 in number, arranged in a double row of
8 each, corresponding in size and spacing to the pins of a double
row header described below. The base connector housing 38 is molded
as part of the base module 4, and the small holes extend vertically
through the housing. Thus, the holes in the base connector 38
extend in the direction of the axis of the electronic energy meter
2, while the terminals 28 extend perpendicular to the axis of the
meter.
Referring to FIG. 2, it is to be noted that the base connector
housing 38, molded as part of the base module 4, extends from the
rim 40, above which the transparent housing 10 is positioned, and
includes a plurality of holes 42 which pass through the top of the
base connector housing to the interior of the generally rectangular
cavity or re-entrant pocket 39 (shown in FIG. 1) formed underneath
the base by the base connector housing 38.
The general configuration of the register circuit board is shown in
FIGS. 3, 4 and 5. Referring to FIGS. 3, 4 and 5, the register
circuit board 50 is configured in the general shape of a truncated
triangle having inwardly tapering sides 52 and 54, and upwardly
extending tab 56 which supports the register connector 60 bearing
female contacts 58 which are sized to mate through openings 64 in
the circuit board with the edge connector 24 of the register module
8. The bottom edge 62 of the register circuit board 50 has two
separated legs 66 and 68 with a cavity 70 therebetween in which are
positioned the 16 pin right angle pin header 72 and an additional 3
pin right angle pin connector 74. The legs 66 and 68 protect the
pins from damage when the register circuit board 50 is being
handled or worked on. It is to be noted that the right angle header
72 is positioned below tab 56 located at the opposite end of
register circuit board 50 such that the pins 78 of the right angle
pin headers 72 are positioned beneath the female connectors 58. The
pins 28 which extend through the register connector 60 are in line
with, but above, the two rows of holes 42 in base connector housing
38.
The various electronic components on the register circuit board 50,
such as resistors 77, diodes 79 and integrated circuits 80, are
provided in accordance with the output functions required. It is a
purpose of the present invention to have the dimensions, mounting
and interconnection of the various register circuit boards 50 for
the electronic energy meter 2 of a standard configuration such that
the electronic circuitry associated with the register circuit
boards may be customized to meet the requirements and demands of a
particular customer or application, while the basic energy meter
remains a relatively standard configuration. That is, a family of
some 6 or 8 register circuit boards can comply with substantially
all customer needs, requirements, and options, and these may be
inserted into the standard energy meter during the final phases of
manufacture, or even added or changed subsequent to delivery of the
meter to the customer. This concept of "late point identification"
of features facilitates the mass production of energy meters and
the stocking of quantities of substantially complete, or completed,
electronic energy meters which may be subsequently customized
through the addition of a selected output printed wiring board from
a group of boards which may be separately stocked in quantity. The
mounting and connecting of the selected register circuit board 50
is readily accomplished by holding the register circuit board at an
angle with the upwardly extending tab 56 slightly away from the
edge connector 24 until the pins 78 are positioned through the
holes 42 in the base connector housing 38. The top of the register
circuit board 50 may then be rotated inwardly, about the pins 78 in
the holes 42 as an axis, toward the edge connector 24. The
extension tab 84 on the intermediate electronic module 6 (best
shown in FIG. 1) protrudes through the opening or slot 86 in
register circuit board 50 to hold and position the register circuit
board. Further rotation of the register circuit board 50 forces the
female connectors 58 of register connector 60 into contact with the
male terminals 28 of the edge connector 24 completing the
connections between the register module 8 and the exterior of the
electronic energy meter 2 below the base module 4 in the cavity or
receptacle 39 (best shown in FIG. 1). The extension tab 84 within
the slot 86 also resists the thrust of the external connector or
plug 120 (see FIG. 6) being pressed into contact with the pins 78.
This relieves the thrust which would otherwise be transmitted
through the register circuit board to the edge connector 24.
Once inserted and connected, the register circuit board 50 provides
a support panel between base module 4, voltage module 6, and the
register 8 aiding in the total integration and support of the meter
assembly.
It is highly desirable that an energy meter be readily configurable
through any of the possible meter forms, including the transformer
rated category, in order to meet the various industry standard
configurations while using the industry standard base prescribed by
the American National Standards Institute (ANSI) standards. In
accordance with ANSI standards, the various circuit terminals such
as 18 and 20 in FIG. 2 are proscribed as to size and location,
along with intermediate row of terminal connectors including
terminals 90, 91 and 92, the general location of which is shown as
terminal 90 in FIG. 1. The ANSI standard S-base meter allows the
pulse initiator KYZ output connections to be made through these
spare meter/circuit terminals. These spare terminals have proven to
be adequate for the more conventional electromagnetic watthour
meter, but have proven inadequate for the signal processing
capability and requirements of an electronic energy meter.
However, it is desirable to provide an electronic watthour or
energy meter with the capability to be completely interchangeable
with existing and installed energy meters. That is, form, fit and
function of the meters should be interchangeable, even though the
electronic energy meter has greatly expanded capabilities and
functions such as built-in test and other functions described
above. Accordingly, the KYZ output connections 90, 91 and 92 are
connected through leads 94, 95 and 96, respectively, to connector
97 which includes female terminals adapted to mate with the
rectangular pin connector 74 on the register circuit board 50.
The KYZ conductors of connector 74 are best shown in FIGS. 3 and 5,
in which FIG. 5 is a cross-sectional view taken along the line 5--5
of FIG. 3. Referring to FIGS. 3 and 5, the KYZ pin connector 74
includes 3 pins 100, 101 and 102, respectively, which are
configured to mate with the female terminals within connector 97
for connection to the KYZ terminals 90, 91 and 92, respectively.
Thus, the subject invention can incorporate a configuration
compatible with existing, or even future, installations which
utilize the KYZ terminals in the meter base. As best illustrated in
FIG. 5, the pins 100, 101 and 102 are attached to the printed
wiring board 50 in a right angle pin header configuration wherein
the pins extend perpendicular to the register circuit board and
then turn a substantially right angle to extend parallel to the
register circuit board 50. This enables the connector 97 to be
mated with the pins 100, 101 and 102 with the connector being
aligned parallel with the register circuit board 50 and positioned
in part between the pins 100, 101 and 102 and the face of the
register circuit board. To further position and secure the pin
connector 74, the header also is formed in an L-shaped
configuration, with the horizontal portion 103 acting as a base and
support for the pins 100, 101 and 102. The vertical portion 104
includes a rounded tip 105 turning inwardly at the free end thereof
which helps position the connector 97, and also assists in
retaining the connector in position once connected. The header 74
is formed of Nylon or similar material and is dimensioned to
provide resiliency through rounded tip 105 which presses against
the connector 97 when it is forced between the pins 100, 101 and
102 and the close fitting vertical portion 104 of the end connector
74.
The details of the reentrant pocket 39 and the connector which
connects to pins 78 from underneath the base 4 are shown by FIGS. 2
and 6. Referring to FIGS. 2 and 6, the commercial 16 pin connector
or plug 120 is secured between the molded members 122 and 124 of
the plug assembly 126. The member 122 includes a pair of ridges or
rails 130 and 132 extending upward. Mating slots 140 and 142 in the
wall of the reentrant pocket 39 (see FIG. 2) receive the rails 130
and 132 to control the insertion and orientation of the plug 120.
The rails 130 and 132 and slots 140 and 142 preclude attempts to
insert the plug assembly 126 into pocket 39 with an improper
orientation.
The member 124 includes a resilient latch plate 166 which is
pivotally secured at its upper end to the member 124. Latch plate
166 is made of stainless steel and includes a projection 172 which
engages a hole 162 in the wall of the reentrant pocket 38 opposite
the wall including slots 140 and 142. The female connectors, such
as 176, make electrical contact with the pins 78 extending through
the holes 28 from the register circuit board 50. The latch plate
166 may be pivoted inwardly by pressure on the bottom of the latch
plate to disengage projection 172 from hole 162, after which the
plug assembly 126 may be removed from reentrant pocket 39 to
disconnect the plug assembly from the register circuit board
50.
The specific electronics included on the output printed board 50
will, as pointed out above, depend on the specific functions and
modes of operation desired, or required, by the customer, and by
the specific installation. There are many potential options such as
the provision of a signal to indicate the end of the demand
interval, a demand threshold alert, pulse initiation, and various
indicating and built-in test functions. However, with only 6 or 8
register circuit boards wide flexibility and versatility may be
realized in meeting substantially all of the common signal
requirements. Thus, the basic energy meter may be built and stocked
with late point identification of specific features for a specific
meter, including later selecting or changing the register circuit
board to meet new or different customer requirements and features.
Removal, and insertion of the same, or a different, output printing
circuit board is simple and quickly accomplished. This also
simplifies repair and maintenance of the boards, and of the energy
meter.
The tapered sides 52 and 54 (see FIG. 3) of the register circuit
board 50 allow the register circuit board to fit closely within the
conical electromagnetic interference and thermal shield which
surrounds it, and which is described in detail in copending U.S.
patent application, Ser. No. 07/412,353 Issue Fee Paid 1/17/91
assigned to the same assignee as the present invention and hereby
incorporated by reference, and is also described in the above
referenced U.S. Pat. No. 5,001,420. The close fit retains the
register circuit board 50 in place. The electromagnetic
interference and thermal shield 15 (see FIG. 1) extends from the
register 8, past and around voltage module 6 to a step 17 (see FIG.
2) in the base 4. There is a close fit between the tapered sides 52
and 54 of the register circuit board 50 and the electromagnetic
interference and thermal shield 15 all along the tapered sides. The
electromagnetic and thermal shield 15 thus assists in retaining the
register circuit board 50 in its connected position, and is removed
prior to disconnecting or removing the register circuit board.
A plastic flap 71 extends from behind and around register connector
60 and hangs down over the electronic components such as integrated
circuits 80, diodes 79 and resistors 77. The flap 71 is made of
mylar and is secured between the top rear of the register connector
60 and the output printed circuit board 50 to provide an insulating
layer over the electronic components. A cutout shaped around
register connector 60 allows the connector to be connected to edge
connector 24 with the flap 71 in place as shown in FIG. 4. The
transparent flap may also include a bar code identifying the
particular register circuit board 50.
The type of terminals 28 and 58 could be reversed with male
terminals 58 in the register connector 60 and female terminals in
the edge connector 24. Thus, while the present invention has been
described through preferred embodiments, such embodiments are
provided by way of example, only. Numerous variations, changes and
substitutions, including those discussed above, will occur to those
skilled in the art without departing from the scope of the present
invention and following claims.
* * * * *